JPH07500779A - Method and apparatus for producing grids from fibers - Google Patents

Abstract

Method and apparatus to form grids of open cells from fibers, especially wood fibers and fibers from waste paper and mixed waste materials. The invention utilizes a screen carrying a plurality of elastomeric pads of predetermined sizes arranged thereon in predetermined spaced relation to each other. The fiber is deposited between the pads but not above the pads. The deposited fibers and the pads are compressed normal to the screen, which causes the fiber in the spaces between the pads to be consolidated both normal and parallel to the screen, resulting in a open grid having cells of the shape of the pads. Numerous variations are provided including several continuous production embodiments. The invention uses state of the art technology for virtually all aspects.

Description

[Detailed description of the invention] name of invention FIELD OF THE INVENTION Method and apparatus for producing grids from fibers The present invention provides continuous The present invention relates to the production of open cell grids. The present invention Using traditional technology and some of our unique patented technologies, we can create structural elements from fibers. It is used to manufacture raw materials.

Background of the invention The present invention makes open cell grids extremely advantageous. and techniques for manufacturing such grids using fibers. Regarding the technique. These fibers include cellulose, various plastics, and glass. It can be of other types, such as fibers, etc. One important advantage of the invention is , it is possible to utilize wood fibers and non-wood fibers that would otherwise not be utilized. .

There are generally two types of trees planted in the United States for commercial purposes: hardwood and softwood. Ru. Softwood is extensively used in the production of paper, newsprint, and other paper products. . Large, high-quality hard water is widely used in timber production.

However, due to relatively small size, some deformation, or other various reasons, the production of lumber Some hard water is not suitable for use.

Furthermore, small branches of trees cannot be used for lumber. The present invention In terms of the use of resources that would otherwise be trash or, at best, only marginally utilized. It concerns an advantageous way to utilize the fibrous resources of the wild forests.

The present invention applies not only to plastic fibers such as polyethylene and polypropylene. , glass fibers, and more “novel” artificial fibers such as aramid. It can also be applied to fibers. These further fibers form their final Depending on the application, the strength, It imparts water resistance and other desirable properties.

In addition to the above-mentioned low-grade trees, branches, etc., the present invention is applicable to all kinds of waste fibers. Another important advantage is that it is possible to utilize fibers. In today's world, There is a very important issue of how waste should be disposed of. Onshore landfill is , are becoming fuller, and regulations on next-generation natural resources are also becoming stricter.

By reusing waste, land-based landfills, air pollution, etc. can be reduced as well. It also saves wood, thereby making full use of our forest resources. becomes possible.

The present invention applies to all types of waste paper, including computer paper, magazines, newspapers, boxes, etc. It is also possible to target cellulosic fibers. Mixed fibers containing both cellulosic fibers and non-cellulosic (artificial) fibers It also works effectively for Paper waste from offices and homes should be Contains many contaminants such as soil, ink, plastic, stable etc. The possibility of obtaining information is an important advantage. This mixed paper waste can be deinked, bleached, etc. for use without the need for pre-treatment and for producing structural products according to the invention. minimal preparatory steps such as removing and screening some of the larger contaminants to All you have to do is process it.

This is the case, for example, when incorporating the grid inside another structural article such as a door. This applies especially to This means that such mixed paper waste and waste From the point of view of reuse, it is possible to utilize unused and unused fiber resources. This is extremely important. Thus, the present invention is lighter but more robust. real fibers of all kinds for the manufacture of new products and components of such products. , without the extra cost of separating non-book fibers and non-book waste. It has the important advantage of allowing waste to be recycled and incorporated into products. .

This invention is the subject of patent no. 7 02. This utilizes part of the technology of No. 870. This U.S. patent is the subject of this application It is related to sharing between people.

The present invention produces a grid that is monolithic and unitary in nature. child These grids are in their final form or substantially in their final form according to the invention. and therefore requires no further assembly and/or additional handling.

A common prior art method of producing honeycomb materials for somewhat similar structures is to or starting from flat sheets or strips of paper-like material, spaced apart from each other. (spaced points), pressurize, and then expand to form a diamond shape. Form a grid of open cells. The present invention provides spaced Substantially different from conventional technology in that no adhesive is required at the location and no expansion process is required. It is different and represents a significant improvement over the prior art. Moreover, the present invention , in that it is possible to manufacture extremely complex structures (for example, see Figure 2). This is a step forward in technology. In the case of the conventional technology, in the entire structure , such complex structures can be avoided in prior art methods because only cell uniformity can be achieved. It is impossible to manufacture a structure.

The present invention also differs from a variety of other paperboard and papermaking apparatus and methods.

An important feature of the invention is that during the forming process the deformation occurs in the direction perpendicular to the direction of pressure and the use of forming elements that compress the fibrous material in a direction parallel to the pressure direction; It is. This is used for egg cartons, cardboard boxes, etc. This is not the case in many other technologies, including manufacturing.

Some forms of the invention are those that produce the material continuously. This is a batch This is a significant improvement over all of the prior art in nature.

Summary and advantages of the invention Manufacturing articles from fibrous materials is a well-developed technology. Main departure This technique varies depending on the nature of the final product required and the particular fiber used. It has the advantage of being able to utilize all techniques.

That is, the fibers can be held in air, water, or other fluids, and curing is In addition, drying can be done by heat, pressure, adhesive, etc. utilizing many different machines and methods for drying or otherwise finishing Can be done. The ability to utilize a large number of prior art techniques is an important advantage of the present invention. That is, by utilizing proven technology and machinery, in accordance with the present invention, an even better product can be produced. It is possible to manufacture

Additionally, the present invention similarly provides specific parameters for a particular application and the particular Depending on the final product, it can be implemented either in a batch process or in a continuous process. Wear.

The present invention, in its simplest form, is based on prior art U.S. Pat. The technology similar to the technology in issue No. 1997-500779 (5) It is something to be used. The present invention provides a base carrier, a The clean or filter consists of a plurality of elastomer pads (elastomer pads) at the base. It is equipped with a mold to which tomeric pads are attached.

These pads are of a predetermined shape and size and are placed in a predetermined relationship with each other on the carrier. It's in charge. On the screen, as will become clear from the detailed description below. The method of selecting the dimensions, shape and spacing of these pads will affect the properties of the finished product. is decided. Carrier fluid moves through the mold and the fibers are attached only between the pads. Fibers are attached to the top of the pad There isn't. These elastomer (preferably silicone rubber) pads not only determines the initial shape of the grid, but also its degree of compaction. It is a key element of the entire process. After the fibers are attached, on the top of the pad The grid is consolidated by applying pressure. When this pressure is applied , the pad contracts in the direction in which the force is applied, but the pad also contracts in the direction perpendicular to the force. expands, thereby reducing the space between the pads where the fibers are placed. Make it smaller. In this way, the attached fibers are consolidated both vertically and horizontally. into an independent cell grid.

Thus, after the grid is formed, the grid is removed and/or cured; It can be used in its original form with some finishing touches. Another aspect of the present invention An example of selection is to insert a first set of pads from the opposite side and insert another set of similar pads. The grid is then inserted into the lid and consolidated twice. As a result, Although it is more robust, it has a shorter and smaller grid than the one formed in the second consolidation process. A finished product is produced with a head bar.

There are no particularly preferred embodiments for single or double consolidation. i.e., convert the grid into a single Also, special In the case of the example, the bar is longer, i.e. thicker in the grill throat, and the finish is It is not important to reduce the strength of the product after such a cycle. Consolidation may be preferable. In other situations, apply pressure twice from both sides. It is sometimes desirable that the green throat produced under that special condition be short; The high density and robustness means that the second pressurization step eliminates the extra effort and cost. considered to be worthy of

However, fiber selection (i.e., some fibers are more robust in nature than others) and/or more tightly bonded), pad dimensions, materials and spacing, operating pressure, etc. Regarding this, considering that the present invention has a wide degree of freedom in selection, it is possible to The selection example is equally applicable to − times of compaction. However, the result of two rounds of consolidation As a result, dimensional accuracy is improved. That is, the dimensions of the twice-consolidated grid are Then, the grid size is more optimal than the grid size due to - times of compaction, i.e., the "design drawing" The dimensions are ``street''.

The present invention utilizes a wide variety of materials and pressures available for manufacturing, resulting in a wide range of properties. manufacture of various products, e.g. products with a certain degree of elasticity and/or cushioning properties. It makes it possible to manufacture.

Another option of the invention is to pressurize the green throat out of the mold after molding. That is. This results in significantly shorter and thicker grid bars. ) is produced. This special property and performance parameter set Coordination may be desirable in certain circumstances. This is due to the versatility of the present invention. It is also another feature.

Another advantage of the twice-pressurized version of the invention is that the second mold, i.e. the second carrier, Alternatively, the elastomeric pad on top of the screen can be designed with close tolerances and The final consolidated shape of the bar within the bar is the shape required for that particular user situation. It is possible to create an accurate shape that approximates .

Another advantage of the second pressurization stage of this double pressurization variant is that after the first pressurization Entrained fibers extending from the grid are forced into the bars and consolidated, leaving the grid The advantage is that both ends of the board can be made extremely smooth. When pressurized for the first time, the appearance may be slightly defective. There are inevitably at least some contaminant fibers present. When the present invention is applied In any case, i.e. due to special circumstances and special requirements of the end use, This may not be important. For example, if the grid is the core of a door , mixed fibers are not a problem.

In a variant of the invention in which the consolidated grid is pressurized and removed from the mold, it is used. The equipment used can include conventional paper presses. These machines are It is applicable to both continuous and batch processes.

The result of this variant has an appearance similar to that of a flat sheet metal sheet with punched holes. , a relatively thin, but highly consolidated closed-cell grid is formed.

However, the performance characteristics of the product of this form of the invention are This is completely different.

These differences are due, at least in part, to the orientation/arrangement of the individual fibers. be. More specifically, in a simple thin plate, the fibers are arranged randomly throughout While in the product of the present invention, most of the fibers have a selected grid pattern. Aligned according to the criteria. Thus fibers within a grid manufactured according to the invention As a result of the fibers being aligned uniformly as a whole, the fibers are more uniformly aligned than if they were irregularly aligned. Relatively high strength can be obtained.

The present invention and prior art U.S. Pat. No. 4,702. The main difference with No. 870 is that this book While the invention produces a closed-cell grid, prior art patents do not disclose the use of this fiber. The point is that it is limited to. This prior art patent has a flange on its side. A three-dimensional structural member is manufactured from the present fibers and has a flat wall. Main departure The versatility of Ming's independent cell grid surpasses the versatility of prior art patented products. It is something that However, the developed technology for embodying the invention of the prior art is This in itself is an important advantage of the present invention. Ru. That is, it is possible to employ proven and developed machines and methods.

Independent grid structures made in accordance with the present invention are described in U.S. Patent No. 4,702,87 This conventional structure is different from the structure manufactured according to the patent No. It can be used for different applications. For example, two liners or plates Bonded to one side of the core to form a sandwich-like panel (core and two liners) When doing so, it is important to have a balanced structure.

In the case of the independent grid of the present invention, two similar liners are placed on one side of the independent grid. As a result of the bonding, a balanced structure is produced. U.S. Patent No. 4. 702.　 This method was used to produce sandwich-like panels with the product No. 870. When joining a liner to the side of a product manufactured by The nature of the side is significantly different. Furthermore, independent grids manufactured according to the present invention are With a smaller radius than the product manufactured by the patent of National Patent No. 4,702,870 It can be rolled. Furthermore, if it is desired that the manufactured structure be transparent, It cannot be used for anything other than the present invention. U.S. Patent No. 4,702. According to issue 870 Solid walls manufactured by Yet another difference is the connections used. When a thin and robust structure is desired that requires minimal adhesive and is lightweight, the present invention A flat independent grid manufactured according to U.S. Pat. No. 4,702.870 preferred over more manufactured products.

Another feature is that when doubly consolidating from both sides of two structures, the independent grid of the present invention In the case of grid bars, the grid bars are more uniform and can be more fully consolidated. This is possible. U.S. Patent No. 4. 702. In the case of No. 870, the ribs are double and processed. Pressing would not provide the same degree of uniformity and compaction.

Many applications are possible for closed-cell grids made according to the present invention. child These grids are used as various insulating materials and cushioning materials for various walls such as furniture and aircraft. It can be used for manufacturing boards. Furthermore, some glues made according to the present invention The lid stacks the bars and cells offset from one another, placing them between them. It is also possible to connect with a thin plate. The composite structure thus obtained is extremely rigid. It is strong, lightweight, and has excellent insulation properties. In this way, the cell is a thin plate Sealed on each side, the thin plates improve the bending and torsion resistance of the composite structure. Ru. That is, the independent cell grid of the present invention has two opposite sides on one side or both sides of the grid. By itself, it resists torsion and bending better than if it were bonded to a thin sheet. It becomes possible to

Another important advantage of the present invention is that the current The point is that the fibers of unused wood chips can be used. Furthermore, the present invention provides such cells Loin fiber alone, non-cellulose fiber alone, cellulose fiber alone, Combinations of fibers and certain non-cellulosic fibers can be used.

For example, polyethylene, polypropylene and other plastic materials for each insert The addition of Give. The method and apparatus of the present invention can be applied to all types of fibers. This is one important advantage of the present invention.

As is clear, internal Instead of solid materials, the independent cell grid of the present invention can be used as core material to produce various products. Manufacturing the product realizes the important advantage of reduced weight. Also, many It is also possible to reduce costs depending on the factors of These advantages are This is achieved while maintaining sufficient strength for the specific product.

Additionally, the advantage of open cell cores is that they are Less material is required to be transported, reducing transportation costs and reducing costs for manufacturers, transporters and final purchasers. This is because it facilitates handling and assembly by persons. For some applications, the strength The weight-to-weight ratio is superior to the maximum strength achieved by solid core. This is an extremely important point. Reduced strength by using closed cell structures This weight can be reduced by minimizing the partitions and structures used in aircraft. It has long been known in the aircraft industry for manufacturing body components and the like.

In order to carry out the method of the invention in continuous form, the machines and techniques of the present state of the art are utilized. This is an important advantage. i.e. for both continuous and batch processes. to distribute the fibers and form a grid, after which the grid is dried and hardened. It is possible to practice the invention using any of a variety of standard machines. Ru. In this case as well, it is possible to embody the prior art into the present invention without much modification. This is one important advantage.

The invention is extremely versatile in all its features. The present invention may be Continuous products can be manufactured in many different dimensions and in all kinds of thicknesses, i.e. the thickness of the entire grid. thickness corresponding to the height of the grid bar) and the thickness of the bars themselves that make up the grid Independent cell grids can be made by It is possible to manufacture a The final product is suitable for containers, household and vehicle structures. For many reasons, including panels, insulated panels and all kinds of other applications. More useful.

Thus, according to the invention, it is well suited for its application purpose and achieves important advantages. Methods and devices are applied which are current and highly adapted to the application.

Brief description of the drawing The present invention may be better understood by reference to the accompanying drawings, which form a part of this disclosure. Goodbye understanding. Referring to attached drawing 1, Figures 1A and 1B illustrate the prior art method for producing expanded independent celluloid nodes. side view and top view showing the method; Figures 2A to 2E illustrate closed-cell single crystals that can be produced according to the present invention. Some of the grids (open cell monolithic grids) Figure 3 shows a modification of the present invention stacked together to produce a composite product. Figures 4 to 8, which show three green throats manufactured by the method, illustrate the principle of the present invention. Figures 9A to 9C show examples of consolidation or IT pressurization from both sides. diagram showing, FIG. 10A and FIG. 10B are diagrams showing a modification example in which pressure is applied outside the mold of the green throat, Figures 11A and 11B show a continuous implementation of the invention showing a machine for depositing fibers. Illustrations regarding examples, Figures 12A to 12F illustrate forming and processing fibers to produce green nods. Figures 1 and 2 show successive embodiments of the invention, illustrating how 13A to 13C show grids manufactured by the continuous manufacturing method of the present invention. FIG. 2 is a diagram showing the drying and finishing status of Description of prior art Referring to FIGS. 1A and 1B, the appearance of the product manufactured according to the present invention is A prior art method of manufacturing an independent cell grid that is similar to is illustrated. Figure 1 The grid 10 of B is generally referred to as a "honeycomb". these honeys The system is made of flat thin plates or strips that are assembled by applying adhesive 14 to the spaced parts. The trip 12 is alternatively made of paper or paper-like material.

The assembly illustrated in Figure 1A is constructed by applying pressure and then allowing time for the adhesive to cure. do. This assembly is trimmed) and then expanded to The structure shown in FIG. 1B is formed.

The present invention offers this particular advantage over the prior art: and many other manufacturing steps, allowing many different types of stand-alone This improves the degree of freedom of selection when manufacturing the grid. The present invention This method differs from the prior art in that the length and width directions can be specially set.

This prior art "honeycomb" material is assembled by applying adhesive 14 to spaced areas. It consists of strips 12 of paper-like material brought together. The strength characteristic parallel to the length of paper is , as shown in Figure 1B, the strength characteristics perpendicular to the length (width direction) are It is something that flows. In the present invention, due to the method of forming fibers between pads, this These fibers are primarily located along the length of the grid bar. For this reason, the square In the case of the pattern, uniform properties are obtained in the length and width directions. hexagon pattern - Uniform in three directions, as illustrated by the arrows in Figures 2A and 2C, for example. have a property. For complex patterns, the main property is the groups in the pattern. Exists along the direction of the lid bar. One advantage of the present invention is that the fibers are formed irregularly, but exclusively, along the length of the Conditions such as a certain length, width or degree of eccentricity (off axis property re the placement position of the grid or the configuration of the pattern that meets the requirements) The point is that it is possible to

The present invention is also different from prior art corrugated boards. Cardboard is a flat fiber. A sheet of fiberboard material is corrugated to form an intermediate core, or corrugated medium. Form in a gated medium). This requires a separate process. Ru. Apply adhesive to one or both sides of the wavy intermediate core, then Or each is bonded to two flat thin plates. The shape of the heart is maintained by the adhesive It will be done. The present invention utilizes this technique in that the fibers are formed directly into the finished shape in one step. It has important advantages over other techniques. Similarly, fibers are connected to the monolithic glynodes of the present invention. To maintain shape or for other reasons, except in specific embodiments where Therefore, the gluing step and the adhesive application step are unnecessary. Furthermore, according to the present invention For example, panels manufactured by grid are more robust and different from cardboard. have a property.

The present invention can be applied to egg cartons, flower pots, basketball throats, buffer ends of fluorescent lights, etc. This is different from a molded article consisting of a regular valve. These products are manufactured using rigid molds. Manufactured. This mold is semi-porous and is filled with screening material (screen ing material) is often coated. Vacuum pressure behind the mold is applied to create a flow through the screen and mold, so that the fibers Form a uniform mat on the screen ball. The mat on this rigid mold is A matching solid mold with the opposite shape (reverse 5haped) is placed on this mat. It is pressed and compacted. This is done by mating the mat with two interlocking molds. compaction between the molds). The direction of the compaction force is perpendicular to the mat. It is towards. In the present invention, the consolidation force is parallel to the bars of the grid and Added vertically.

Detailed description of the preferred embodiment Referring to FIGS. 2A through 2E, a The various forms of green throat are shown.

In FIG. 2A, grid 16A is a hexagonal closed-cell structure. Figure 2 In B, this grid 16B is superimposed or arranged in brick wall style rows. formed from rectangular sections placed In FIG. 2C, the grids 16C are It is formed from rectangular cells arranged in a rectangular manner. In the second diagram, grid 1 6D has square cells, but these cells are arranged in rows half the size of one cell. They are staggered within.

FIG. 2E shows the shape of the mixed cell.

In all of these Figures 2A to 2E, the dotted lines indicate that the grid has an indefinite length. and/or width dimension.

FIG. 2E illustrates yet another important feature of the versatility of the present invention. The present invention It is possible to place fibers in different parts of the same structural element, thus imparting strength. It is Noh. Referring to FIG. 2E, grid 16E includes cells of many different dimensions. The cells of various sizes have different shapes and relationships with each other.

The grid 16E has small rectangular cells, large rectangular cells, and large rectangular cells. Includes triangular cells cut in half and rectangular cells of various sizes. Similarly, The dotted lines have shape, length and width dimensions in accordance with the other teachings of the invention described herein. It shows that the law is indefinite.

From FIG. 2E, it can be seen that the variations of grids that can be manufactured according to the invention are almost infinite; The limit is determined only by the creativity of the designer and the force required to impose it. That is understood.

As is clear from these figures, any type of configuration can be employed. cell Triangular shapes, hexagonal shapes and all kinds of other geometric and non-geometric shapes It can be of any mathematical shape. The variations are literally endless.

One important feature of the present invention is that various structural and non-structural products are lightweight and In many areas of residential construction and commercial buildings where high-strength nozzles are required, such as the heartwood of doors or lightweight office furniture used in This is a point that can be adopted to manufacture products. Products other than structures and such products As a structural element, lightweight, low-density structural grooves are required in various locations. Cushioning thin plates used in places, insulation thin plates , insulation products and similar products.

FIG. 3 shows such a composite panel. Three grids 16 in Figure 2A A is shown by way of example only. Use any other Gri Nodo It is also possible to use combinations of such grids or multi-layer structures. It can also be used. Using an inner sheet 38 of any suitable material, the three The two grids 16A are bonded together. The middle Gri Nod 16A is the other two It is understood that the rotation is 90° with respect to the outer layer of. Various intermediate grids angle to balance the length and width properties of the panel, or other can be set in a certain way or improve certain properties along a certain direction. .

Another advantage of a multi-grid structure as illustrated in Figure 3 is that it provides excellent insulation. Significantly improved - or using multiple grids to fill the cells with suitable material By doing so, it is possible to insulate both sound and heat. Also, flame retardant material can be used to fill cells and realize important advantages in composite structures and other It is also possible to realize the advantages of The optional filling of this cell is shown in Figure 3. It is. Also, when the panel is closed, for example in the case of a door, the entire It is possible to fill the cells of any grid.

Although the grids may also be bonded directly to each other, the sheets 38 may be The strength of the composite structure when combined with a grid manufactured by The use of such a sheet 38 is desirable for increased strength.

4 to 10 illustrate the basic principle of operation of the present invention. of this description Before we begin, it may be useful to define some terms.

A grid made according to the invention is shown in FIG. See these drawings We can then assume that the grid has one surface. Multiple cells are axis , and these cells are perpendicular to the plane of the grid. Multiple bars fill a cell and together form Glinod. The thickness of the bars of the grid is Measure perpendicular to the plane, ie parallel to the axis of the cell. grid bars The height of sets the overall thickness of the grid.

The present invention is based on prior art U.S. Pat. 702. Many of the same devices as No. 870 Take advantage of. Compare Figure 1 of this U.S. patent with Figures 4, 5, and 7 of the present invention. do. Thus, in its simplest form, the present invention provides a A carrier 18 that supports the pad 20 is provided. The carrier 18 is made of a suitable metal. , or a screen formed from synthetic material.

Referring to FIG. 4, the fibers 22 are placed on a carrier, screen or support 18. and is carried by a suitable carrier fluid flowing around the pad 20. The attachment of this fiber The attached state is illustrated in FIG. 4, and arrows indicate attached fibers and carriers, or A carrier fluid, air, water or other fluid flows through the screen 18. Show direction. FIG. 5 shows the end of the fiber deposition stage. used The amount and type of fibers applied and provided within the carrier fluid are as illustrated in FIG. to ensure that the fibers only fill the spaces between the pads and do not attach to the tops of the pads. Set to . 5 and prior art U.S. Pat. No. 4,702,870. As can be seen by comparing FIG. 3 with the prior art U.S. Pat. This is one of the main differences with No. 2,870.

However, referring again to FIG. 5, the present invention completely eliminates the space between the pads. It should be noted that it is not limited only to filling. Specific applications of the invention An example is only a portion of the space between the pads, e.g. half of it, or a third of it full. Sometimes you only need to fill it up. Such selection is a technique that can be easily devised by a person skilled in the art. range. This variation, i.e. filling only part of the space between the pads, - The use of sets of pads on a screen with grids of different dimensions and performance characteristics. It is permissible to manufacture

FIG. 6 shows the compaction of the fibers deposited between the pads 20. this For this purpose, pressure means 24 are provided. The pad 20 is placed on the surface of the grid to be manufactured. and is compressed by a force applied perpendicularly to the screen 18. . This condition is illustrated by the force arrows in FIG.

The present invention is part of the same apparatus and technology as prior U.S. Pat. No. 4,702,870. while also using different technologies. Important differences, applied pressure and power The type of rubber used for the pad 20. For example, U.S. Patent No. 4,702,87 Referring to Figure 10 of No. 0, when consolidation occurs, the sides of the pad are approximately curved. It can be understood that the shape is Referring to the corresponding FIG. 6 of this application, the package The sides of the grid are as required for manufacturing the bars of the grid manufactured according to the invention. It has a substantially linear shape. First, overall, the present invention High pressure is used. In prior art patented inventions, the working pressure is usually 1 00 ps i or less, and a range of 25 to Loops i is described. Book In the invention, the working pressure is usually 100 ps i or more, and the effective range is 1 00 to 500 psi. However, this range is not the limit. The present invention It is also used to produce grids at pressures as low as 3 ps i. Furthermore, yo It is considered that it is possible to use extremely high pressures such as 500 psi or more. It will be done. In accordance with the teachings of the present invention, high pressures as high as 1°000 psi are utilized to achieve good results. It is believed that it is also possible to obtain results.

Further, when applied commercially, the present invention is disclosed in U.S. Patent No. 4. 702. No. 870 It is conceivable to use a softer grade of rubber for the pad 20. this In the present invention, the grid bar can be made more straight and the straight side of the pad can be This is effective in making the section more straight. However, in the present invention, substantially linear side parts are often desirable, and therefore take advantage of the greater pressure and differences in rubber composition. Thus, the object of the present invention can be achieved.

As shown in the drawing, the pad 20 receives pressure while maintaining a substantially linear shape. is compressed and deformed outward parallel to the screen. In this way, the grid The dobber is consolidated both vertically and horizontally.

This vertical direction corresponds to the bar height of the grid to be manufactured, and also the horizontal pressure Densification corresponds to the thickness of these bars. In FIG. 7, the pressurizing means 24 is removed, The pad returns to its relaxed state so that the consolidated grid is attached to the pad 20. Shown in place on top of the mold.

The force arrows and pressure means 24 illustrated in FIG. a platen that applies pressure to consolidate the grid, as known to those skilled in the art; , rollers or other means.

FIG. 8 shows grid 16 removed from the mold. The bar 28 is The bars form independent cells therebetween.

- The grid 16 produced by pressing only from the sides is different from the one shown in FIG. It can be used similarly.

However, in some applications and for certain fibers or mixtures of fibers, the bar Shorter than the one shown in Figure 8, but denser and more robust. It is desirable to manufacture grids. Such a grid 16-2 with bars 32 is shown in FIG. 9C.

The manufacturing method is shown in FIGS. 9A and 9B.

To perform the second consolidation or pressurization step, reference may be made to FIG. Figure 4 The grid 16 produced at the end of the method of FIG. A group formed on the opposite side from the support 18 is inserted into a second mold made of 2OA. The sides of the lid bar are adjacent to the support 18A and between the elastomer pads 2OA. There is a bar. The dimensions of pad 2OA are as follows: The dimensions of the head 16-2 can be more accurately controlled. similarly , the spacing between the pads 2OA may be different from that shown in FIGS. 4 to 7. I can do it. That is, if it is necessary to subject the force of the second pressurization stage, the final glue In order to control the shape of the lid 16-2 and its bar 32, the method of the present invention Further versatility can be achieved. Based on Figure 9C, this It may be useful to compare the drawing with FIG.

As can be understood from the comparison between Figures 8 and 9C, consolidation or pressure is applied from both sides. For panels manufactured in accordance with embodiments of the invention, the ribs are short and the bars 32 are The bar 28 is significantly denser than the bar 28 produced by only one round of consolidation or pressing. It can be seen that it is very robust. Also, in Figure 9C, the double pressurized grid is Indicates that it was consolidated or pressurized from the side, and was pressurized only from one side. To distinguish it from the grid 16, it is designated by a different reference numeral 16-2. This reference mark Reference number 16-2 is used again in other figures and herein.

This second stage trade-off is based on its cost and eff ort), this causes the difference between the two products. That is, additional strength is required. If the size is smaller and the larger dimensions are more important, a single consolidation (Fig. ure 8 single consolidation bars) is more desirable. Delicious. On the other hand, in other end use situations, it is smaller and more dense. , the more robust bar of Figure 9C is worth the additional effort of a second compaction. .

Grid 16 is inserted from opposite directions into a mold consisting of parts 18A, 2OA . Next, the pressurizing means 24 is attached by the method shown in FIG. In this way, the ninth The consolidation process utilizing Figure B is similar to that described below with respect to Figure 6. However, there are the following differences.

The grid 16 produced in both cases, i.e. at the end of a single pressing step, or is then applied to the grid 16-2 produced at the end of the double pressing step. Allow the adhesive to dry and cure any adhesives used within the normal technical range of this technique. Apply other finishing processes to complete the grid 16 or 16-2, and Turn the grid into a finished product. When using non-cellulosic products, the actual Some of the fibers may be melted and the mat may be hardened into the grid 16 or 16-2. can.

When employing the second pressurization procedure of FIG. 9, the grid 16 is It is desirable to reverse it for the space. There are many reasons for this.

One reason is that the pressure discontinuity, or pressure difference, that occurs during the first pressurization stage is This is because when the grid is inserted in the opposite direction, it is compensated by the second pressurization stage. .

This reverse procedure can also be used to fill in the top and bottom of the grid bar. ets), i.e. straight and flattened by the second pressurization. Guri Nodhar is formed. Moreover, the grid 16 manufactured by - times of pressurization Fiber inclusions, which are a problem in 9, which results in a tighter ne ater), a clean looking grid is formed.

Yet another selection example is shown in FIGS. 10A and 10B. In this case, the grid changes in its properties after formation but before curing or other finishing. This grill The head 34 is formed by the green nod 16 formed by two pressurizations or by double pressurization. The grid 16-2 can be formed using any of the following methods. This grid is It is removed from the mold and placed itself in the pressure means 24. Grid from mold Sufficient to remove and move to a processing station as illustrated in Figure 10A. At least one pressurization step may be required to ensure that sufficient strength is obtained. . The grid 34 thus formed is shown in FIG. 10B. this place In some cases, final steps such as drying and curing are necessary to produce a finished product. is required.

The basic principle of operation of the invention, illustrated and described in FIGS. 4-10, is that It is applicable both to process or continuous process. The remaining figures 11, 12 and Other variations and further teachings regarding embodiments of the invention are illustrated in FIG. Here, the grid with - times consolidation and the grid with double consolidation Both are manufactured in a continuous manner.

FIG. 11 shows two different manufacturing methods for depositing or forming the grid. Ru. Figure 12 shows several different variations of pressing and shaping the grid. It is. FIG. 13 shows some steps for drying and curing or finishing the grid. A modified example is shown below.

Either of the two forming methods shown in Fig. 11 can be applied to Fig. 12 A, Fig. 12 B, or Fig. 12 C. It is within the scope of the teaching of the present invention that the present invention can be adopted in relation to This is an example of sex. If it is desirable to apply pressure from both sides, please refer to Figure 12A or Figure 1. After any process in Figure 2B, perform the process in Figure 12D1, Figure 12E or Figure 12F. I can continue. The drying of the grids shown in Figures 12A to 12E is shown in Figure 13. This can be done by one of the following methods. The exact combinations available are shown in the drawings, Regardless of the desired end result, dimensions and other parameters surrounding the specific usage situation. Determined by

FIG. 11 shows two continuous manufacturing methods that can be employed in the present invention. be. FIG. 11A shows the Fourdrinier molded part (Fourdrinier fo simplification of the molding part known in the art as rming 5ection) This is a drawing. FIG. 11B is a simplified drawing of a cylinder forming machine. Main departure Any of the above can be used in accordance with the teachings of the present invention. Element 40 illustrated in Figure 11A on a moving belt in a manner more or less conventional for this type of equipment. A vacuum box or the like to assist in forming the grid 16.

In Fig. 12 A1, Fig. 12 B, and Fig. 12 C, the cylindrical body manufacturing machine (a cy linder forming machine) has three different types of pressurization. It is shown in combination with the device. Similarly, the Fourdrinier molding in Fig. 11A It is possible to use parts. Similarly, other means known in the art It is also possible to adopt

In Figure 12A, on the cylinder former Only certain special screens are shown.

A press 34 is located at the top of the cylinder and presses the fiber mat and elastomer pad. Pressurize the door 20. The fiber grid is then lifted from the screen and rolled. It has sufficient strength to be transported to roll presses 36. Ru. These rolls 36 are the counterbalance part of the pressure means 24 in the previous figure.

The result of this method of FIG. 12A is similar to grid 34 of FIG. 10B, i.e. , a relatively thick short and low grid is formed.

In Figure 12B, special screens are placed along the perimeter of other screens. It extends out of the forming cylinder and then returns to the underside of the cylinder. The large diameter press 36 Beloit Corporation of Beloit, Wisconsin. A prior art elongated nip press (n ippress).

roller, or more precisely with regard to this drawing, shoenip ) is shown at 36 in FIG. 12B. roller nip More positive pressure device (roller nip pressing device) A precise schematic diagram is shown in Figure 12. These two are interchangeable. However, in many cases the shoenip shown in Figure 12B is preferred.

In Figure 12C, a special screen is transported together with the grid into one of the drying stages. It will be revealed. That is, a special screen supporting the pad is used during the forming, pressing and curing stages. It is long enough to extend through the storey. The curing stage is performed in any of the forms shown in Figure 13. 12A and 12B.

Figure 12, Figure 12E, and Figure 12F include the two diagrams in Figure 9B and Figure 9C mentioned above. Three of the numerous means of producing grid 16-2 by heavy consolidation or pressurization are shown. It is. As mentioned above, the second set of pads was inserted with the first set of pads. Consolidated Gri-nod 16 from the opposite side (but before hardening and finishing) and then subjecting the first grid 16 to a second consolidation or pressurization step; A second Gri Nod 16-2 is manufactured.

In Figure 12, the manufacturing process starts from either the stage of Figure 12 A1 or Figure 12 B. The grill throat structure 16 is attached to the drum as shown in the drawing. - fed into a press 36 with a throat; These pa-nods are the first set of pa-nods. See the explanation of this point regarding kunodo (of the two sets mentioned above), which is slightly different from kunodo. and). Grid 16 using press felt 42 to facilitate gently pressing the already formed cells inside into the pads on top of the drum 36.

As mentioned above, this drum may be a shoe nip as illustrated in FIG. 12B, or may be a roller drum as shown in the twelfth diagram. Currently, Shuni Whether this is considered better depends, of course, on the parameters of the particular implementation used. It is thought that it is determined by the tank. Furthermore, using the pressure felt 42, Absorption of water or other fluids that may be present in the undried green throat 16 I can do it.

These nodules in Fig. 12 A1, Fig. 12 E, and Fig. 12 F are pressurized - times and glued. Insertion side of Fig. 12 A1 Fig. 12 B or Fig. 12 C when forming the lid 16 It should be noted that the pads inserted from the opposite side are shown.

In FIG. 12E, a second set of pads is connected to a continuous or closed loop screen. ed1oop5clean) 44 is shown. child The working method and product are the same as those in Figure 12, including the felt 42 described above. It is.

As explained with reference to FIGS. 12A to 12E, with reference numeral 16 or 16-2. The produced grid shown is sent to the apparatus of FIG. 13 for drying and finishing. No. Figure 12F shows a continuous pressure drying device (a continuous press A second combined pressurization and drying mechanism comprising a dryer) 46 is shown. . Also, the driver is fitted with a continuous screen to support the pad for the second pressurization. A dryer felt 43 is also used. The mechanism in Figure 12 F is , applying continuous pressure and, if desired, heating, the final product of FIG. raised grid, i.e. any variant of Figure 13 can be used with Figure 12F. do not have to.

FIG. 13 shows various drying or curing mechanisms that can be used with the present invention. This is an indication. Other conventional means may also be used.

Figure 13 shows a high velocity hot air impingement dryer (a high velocity impingement dryer). hot air impingement type of dryer) is shown, where hot air is blown from the top and/or bottom to blow the fiber grid. Dry the fiber grid. In this configuration, the pressure is applied to the grid Note that it is never attached at right angles to the

Figure 13B shows a drum dryer, such as that used in the paper industry. A typical structure of yer) is shown.

In this case a slight pressure is applied at right angles to the grid. This is true Although desirable in some situations, it may not make sense at all depending on the particular grid being manufactured. Sometimes there isn't. That is, there may be cases where there is no effect.

Finally, FIG. 13C shows a continuous press. Continuous presses are used for paperboard and Used in industry to make particleboard and particleboard. Continuous press High pressure can be applied perpendicular to the grid during the drying process. Figure 13 In three embodiments, the grid can be used alone or the grid can be used as a screen. The grid can be finished using drying/hardening and other means.

Although the invention has been described in some detail, this detailed description is only one example of the invention. However, the scope of protection of the present invention is limited only by the spirit of the invention and the scope of the claims. It is something that should be judged.

FIG, IA 6A FIG, 2B FIG, 2E FIG.3 FIG, 11B FIG.8 FIG, l0A FIG, 10B FIG, 12B FIG, 12E FIG. 13A

Claims (27)

[Claims] 1. whose thickness is parallel to the plane of the grid and whose height is from the fibers How to manufacture independent cell grids with multiple bars to set the thickness of the grid , providing a porous carrier and providing a plurality of pads on the carrier; providing each of the pads with variable dimensions and shapes; positioning the heads on the carrier in a predetermined spaced relationship with each other; forming pads from an elastomeric material and reducing the spacing between said pads; depositing fibers on the carrier so that they can be at least partially filled; and a carrier fluid is discharged through the attached fibers and said carrier. performing the step of attaching said fibers to said carrier using rear fluid technology; consolidating the attached fibers both in a direction perpendicular to and in a direction parallel to the , perpendicular to the carrier on the pad, at its end remote from the carrier; The pad is expanded parallel to the carrier by applying pressure in the direction of The bars of the grid are compressed in both the thickness direction and the height direction, and the consolidation step by providing substantially straight sides to the bar of the lid; A method comprising: a step of performing; 2. A method according to claim 1, wherein after said consolidation step, the finished grout is The produced grid is cured and dried to the extent necessary to produce the lid. The method further comprises the step of: 3. 2. A method as claimed in claim 1, in which the entire process starts with the deposition step. All stages are continuous, thereby making it possible to manufacture the grid as a continuous product. A method characterized by: 4. The method according to claim 1, wherein after the first consolidation step, the produced performing a second consolidation step on the grid; and performing a second consolidation step on the pad; After the first consolidation step, the second consolidation step is carried out by separating the produced grid. and predetermined dimensions and shapes of each of the first set of pads. a second set of pads having a second predetermined size and shape substantially similar to and the elastomeric material of the first set of pads is similar or forming the pads of the second set of pads from the same elastomer material; and positioning the pads of the second set of pads in a predetermined spaced relationship with each other. and all of said steps begin with execution of said second consolidation step. and the bars of the grid after the second consolidation stage are A method characterized in that it is shorter, thinner and denser than the subsequent bars. 5. A method as claimed in claim 4, in which the second set of pads is provided with support. providing a support, and providing sloped sides to the pads so that two adjacent pads The cross-sectional shape of the space between the pads corresponds to the pair formed by the first set of pads. during said first consolidation step. the position of the grid relative to the first set of pads; The position of the grid with respect to the second set of pads during the densification stage is upside down. A method comprising: 6. A method as claimed in claim 5, wherein the green after the second consolidation step is the height of the bars of the rod is about 25% lower than the height after the first consolidation step; A method characterized by: 7. A method as claimed in claim 1, wherein the pressure employed during said pressure application step is A method wherein the force is in the range of about 25 psi to about 500 psi. 8. A method according to claim 1, wherein the grid is attached to the carrier and the front. Grid produced after the first consolidation step by separating against the pad performing a second consolidation step on the grid and parallel to the height; applying pressure to the bars of the rod, which causes said bars after the second consolidation stage to and a step of making the material shorter and thicker than after the consolidation step. How to do it. 9. An independent cell grid produced by the method of claim 1, wherein the fibers are Fibers made from wood and wood products, fibers from cellulosic materials, paper waste and paper waste fibers from industrial products, fibers from mixed waste materials, fibers from man-made materials, and / or a combination thereof. dd. 10. A grid according to claim 9, wherein a plurality of said grids are made of an adhesive. and are interconnected by an intermediate sheet to form a structural panel. grid. 11. A grid according to claim 10, wherein at least three of the grids grids are interconnected and at least one central grid is in its own plane. rotated relative to both of its juxtaposed grids, thereby Guritsudo is characterized by increasing the strength of the flannel. 12. The grid according to claim 11, wherein the cells of the grid are hexagonal, and the at least one central grid is rotated by 90°. Grid to mark. 13. A grid according to claim 10, wherein the insulating material is A grid characterized in that the grid is provided within at least one grid cell of the grid. . 14. The grid according to claim 9, wherein the grid has a plurality of cells. Grid characterized by different dimensions and/or shapes. 15. whose thickness is parallel to the plane of the grid and whose height is from the fibers For equipment that produces independent cell grids with multiple bars that set the thickness of the grid. a porous carrier means and a plurality of pads on the carrier means; a pad, each of which has a predetermined size and shape; positioning means for positioning on the rear in a predetermined spaced relationship from each other, and an elastomer - depositing the fibers on the carrier; an attachment means that fills only at least a portion of the space between the attached fibers; carrier fluid technology with a carrier fluid discharged through the carrier and the carrier fluid. the carrier on the pad at right angles to the carrier; The deposited fibers are removed from the key by applying pressure to their ends facing away from the key. a compacting means for compacting both in a direction perpendicular to the carrier and in a direction parallel to the carrier; the pad is expanded parallel to the carrier, and the pad is expanded parallel to the carrier. The bars of the lid are compressed both in their thickness and height directions, and the bars of the grid are A device characterized in that it imparts substantially straight sides to the bar. 16. 16. The apparatus of claim 15, wherein the predetermined dimensions of the pad and and the shape is square, rectangle, hexagon, other geometric and non-geometric shapes, mixture of shapes, mixture of all dimensions of one shape, and/or mixture of both dimensions of one shape and/or a mixture of said shapes. 17. 17. The device according to claim 16, wherein the killer means is made of metal and metal. The screen is made of a material selected from the group consisting of A device used as a sign. 18. An apparatus according to claim 15, wherein the consolidated grid is required. means for curing and drying accordingly, thereby producing a finished grid. A device further comprising: 19. An apparatus according to claim 15, in which the grid is a continuous product. An apparatus further comprising continuous manufacturing means for manufacturing. 20. The apparatus according to claim 19, wherein said continuous manufacturing means both One of a four-drinier molding machine and a cylinder molding machine having said pad thereon. A device characterized by comprising: 21. The apparatus according to claim 20, wherein the continuous manufacturing means comprises at least A device characterized in that it is also equipped with a cylinder press or a shoe nip press. 22. The apparatus according to claim 20, wherein the continuous manufacturing means comprises at least It is also characterized in that it further comprises a hot air dryer, a drum dryer or a continuous press dryer. A device used as a sign. 23. The apparatus according to claim 15 or 19, wherein the compacting means , the grid produced after the first consolidation for the first set of pads; separating means for separating and each pad having predetermined dimensions and dimensions for each pad of said first set of pads; a second set of pads having a second predetermined size and shape substantially similar to the second set of pads; E, the pads of the second set of pads are elastomer of the first set of pads. made of an elastomeric material similar or identical to the tomeric material of said second set. positioning the pads of the pads in a predetermined spaced relationship with each other; wherein the bars of the grid after the further consolidation are the same as the bars of the grid after the first consolidation. - A device characterized by being shorter, thinner and denser than -. 24. 24. The apparatus of claim 23, further comprising support for said second set of pads. the first set of pads further comprising a body, the pads having sloped sides formed therein; The cross-sectional shape of the space between two adjacent pads of the second set of pads is of said first set in said first consolidation for the second consolidation compared to the position of the grid relative to the pad; The method further includes means for inverting the grid with respect to the second set of pads. A device characterized by: 25. 24. The apparatus according to claim 23, wherein said green after said further consolidation is The bar of the rod is about 25% lower than the first consolidation height. A device that does this. 26. 24. The apparatus of claim 23, wherein the first and second sets of packs are the pads have sloped sides and a space between two adjacent pads of said second set of pads; the cross-sectional shape of the space is smaller than the corresponding space of the first set of pads; A device characterized by: 27. The apparatus according to claim 15 or 19, wherein the first compaction The pressure applied by the means is in the range of about 25 psi to about 500 psi. A device featuring: